CN114559116B - Regulating and controlling method and tool for large-area molded surface electrolytic machining flow field - Google Patents
Regulating and controlling method and tool for large-area molded surface electrolytic machining flow field Download PDFInfo
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- CN114559116B CN114559116B CN202210199866.4A CN202210199866A CN114559116B CN 114559116 B CN114559116 B CN 114559116B CN 202210199866 A CN202210199866 A CN 202210199866A CN 114559116 B CN114559116 B CN 114559116B
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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Abstract
The invention relates to a regulating and controlling method of a large-area molded surface electrolytic machining flow field, which comprises the following steps: adjusting the pressure gradient of an electrolyte outlet by adopting a flow resistance type regional pressure method; adding a reverse pulse during an intermittent window of forward pulse application; and determining the parameters of the electrolytic machining process according to the material removal characteristics in the machining process. The invention also relates to a large-area molded surface electrolytic machining tool which comprises a cathode mounting seat, a machining cathode, a small-end pressing plate, a base, a large-end pressing plate, a water jacket, a regulating plate group and a pressure acquisition point group; the small end pressing plate and the large end pressing plate are both arranged on the upper end face of the base and used for fixing a workpiece blank on the base, and the machining cathode is in contact with the workpiece blank for tool setting and is located between the small end pressing plate and the large end pressing plate. The method for regulating and controlling the flow field in the large-area molded surface electrolytic machining aims to solve the problems that the electrolytic machining products are difficult to discharge and the polarization phenomenon is difficult to eliminate due to large electrolyte flow difference in the large-area molded surface electrolytic machining process.
Description
Technical Field
The invention relates to the technical field of an electrolytic machining process, in particular to a method and a tool for regulating and controlling a large-area molded surface electrolytic machining flow field.
Background
The electrochemical machining is a special process method for removing and machining metal materials by utilizing an electrochemical anode dissolution principle. The method has the advantages of wide processing range, no cathode loss, no limitation of material hardness, high processing efficiency, good processing surface quality and the like, is widely applied to the manufacturing of the fields of aerospace, weapons and the like, and plays an irreplaceable role in the manufacturing of key parts related to aeroengines in particular. For example, the efficient and low-cost manufacturing of the integral blade disc of the aero-engine is realized by using an efficient and precise electrolytic machining method, and the method is also an important method for realizing efficient machining in the manufacturing of key parts such as a large thin-wall casing, a rectifier, a blade and the like.
In the electrolytic machining process, metal on the machined surface of the workpiece anode is dissolved at a high speed according to the shape of the tool cathode, meanwhile, the workpiece in the solution is passivated to form a plurality of positive ion colloidal particles and flocculent loose sediments, and when the workpiece is not easy to wash, the sediments are electrophoretically transferred from the acid anode area to the alkaline cathode area and decomposed, adsorbed and bonded on the surface of the tool cathode under the influence of the cathode potential, so that the macroscopic and microscopic shapes of the tool cathode are changed, and the potential difference between the cathode and the anode, namely the polarization phenomenon, is caused. For some materials with high sensitivity to the electrolyte, such as titanium-containing metal materials (pure titanium, TC4, etc.), when a workpiece of such materials is electrolytically machined, a dense passivation film is relatively easily formed on the surface of the workpiece, and the generation of the passivation film can prevent the electrochemical reaction from proceeding, i.e., another polarization phenomenon — passivation.
In the large-area molded surface electrolytic machining, because the electrolyte flow is long, the electrolyte flow field distribution is difficult to reach a uniform state, electrolytic products, bubbles, heat and the like generated in the traditional electrolytic machining cannot be discharged in time, the probability of occurrence of a polarization phenomenon is increased, the machining process cannot be carried out, or flow marks, scars, short circuit burns and the like appear on the surface of a workpiece, and even the product is scrapped in severe cases.
In the electrolytic machining of the large-area molded surface, because the machining area is large, the flow of electrolyte is long, the content of electrolytic machining products, bubbles and the like is gradually increased along the flow, the resistance at a machining gap is increased, the conductivity is gradually reduced along the flow, the current density is correspondingly reduced along the flow, the material removal rate is changed, the machining gap is also gradually changed along the flow, and the forming precision and the surface quality of the electrolytic machining are directly influenced. In addition, in the electrolytic machining process of the large-area molded surface, ions are easily gathered on the surface of the electrode to form ion adhesion, and the more the ion adhesion on the surface of the electrode is, the more the concentration polarization is serious; if the electrode surface 'ion adhesion' is not uniform, concentration polarization is not uniform; so that the local current density is reduced or distributed unevenly, affecting the material removal rate and thus the machining accuracy and the surface quality.
Particularly, in the electrolytic machining of titanium alloy workpieces which are easy to passivate, the problems are particularly outstanding, small gap (0.03-0.1 mm) machining cannot be realized, the machining gap can be kept at the level of 0.5-0.8 mm, the stability of the machining process can be maintained, and the machining efficiency, the forming precision and the surface quality are difficult to guarantee.
In the traditional electrolytic machining, an integral water retaining device is generally arranged at the bevel edge of a workpiece to form back pressure, so that the uniformity of a flow field of a machining area can be effectively ensured in the small-area molded surface electrolytic machining; however, in the electrolytic machining of a large-area molded surface, the size of the molded surface of a workpiece is changed greatly, and the difference of different regional processes is large, so that the integral back pressure mode cannot meet the machining requirement, and the problems of short circuit, burning and the like caused by uneven flow field, lack of electrolyte and the like are easy to occur at the corner position of the long-process molded surface.
Therefore, the inventor provides a regulating and controlling method and a tool for the electrochemical machining flow field of the large-area molded surface.
Disclosure of Invention
(1) Technical problem to be solved
The embodiment of the invention provides a regulating method and a regulating tool for an electrochemical machining flow field of a large-area profile, and solves the technical problems that the electrochemical machining flow field is not uniformly distributed due to the approximate difference of electrolyte flows in the electrochemical machining process of the large-area profile, the discharge of an electrochemical machining product is difficult, and the polarization phenomenon is difficult to eliminate.
(2) Technical scheme
The invention provides a regulating and controlling method of a large-area molded surface electrochemical machining flow field, which comprises the following steps:
adjusting the pressure gradient of an electrolyte outlet by adopting a flow resistance type regional pressure method;
adding a reverse pulse during an intermittent window of forward pulse application;
and determining the parameters of the electrolytic machining process according to the material removal characteristics in the machining process.
Further, the method for adjusting the pressure gradient of the electrolyte outlet by adopting the flow resistance type regional pressure method specifically comprises the following steps:
a branch partition adjusting device is arranged on the electrolyte outlet in a direction vertical to the electrolyte flowing direction;
according to the change situation of the electrolyte flow field state caused by the shape change of the workpiece processing surface in the processing process, a plurality of pressure collection points are arranged along the process;
and adjusting the space size of the flow dispersion area at the on-way electrolyte outlet in real time according to the pressure change condition of each pressure acquisition point.
Further, the adding of the reverse pulse in the intermittent window period of the forward pulse application specifically includes:
the reverse pulse is applied during the intermittent period of the forward pulse processing, so that a positive pulse and a reverse pulse are alternately applied to the workpiece anode and the tool cathode.
Further, the application mode of the reverse pulse comprises the following steps: positive pulse falling edge application, positive pulse pause application, and simultaneous application of positive pulse falling edge and positive pulse pause.
Further, the determining of the parameters of the electrolytic machining process according to the material removal characteristics in the machining process specifically comprises the following steps:
the processing process is divided into three stages of removing a thin oxide layer on the surface, quickly leveling and precisely forming, and processing technological parameters of the corresponding stages are respectively determined.
Further, the processing process is divided into three stages of removing a thin oxide layer on the surface, quickly leveling and precisely forming, and processing technological parameters of the corresponding stages are respectively determined, and the method specifically comprises the following steps:
determining the electrolytic machining voltage and the cathode feeding speed required by removing the thin oxide layer on the surface, quickly leveling and precisely forming through a machining test;
respectively determining a first relation curve and a second relation curve according to the electrolytic machining voltage and the cathode feeding speed;
leading the first relation curve into an electrolytic machining power supply control system, and leading the second relation curve into an electrolytic machining machine tool control system;
during electrolytic machining, the electrolytic machining power supply control system outputs machining voltage according to the first relation curve, and a machine tool spindle drives the cathode feeding speed to automatically adjust according to the change of the second relation curve along with machining time;
the first relation curve is a relation curve of processing voltage and processing time, and the second relation curve is a relation curve of cathode feeding speed and processing time.
The invention also provides a large-area molded surface electrolytic machining tool which comprises a cathode mounting seat, a machining cathode, a small-end pressing plate, a base, a large-end pressing plate, a water jacket, a regulating plate group and a pressure acquisition point group; one end of the machining cathode is fixed on the cathode mounting seat, the small-end pressing plate and the large-end pressing plate are both mounted on the upper end face of the base and used for fixing a workpiece blank on the base, and the machining cathode is in contact with the workpiece blank, adjusts a tool and is located between the small-end pressing plate and the large-end pressing plate so that electrolyte can flow directionally along the molded surface;
the cathode mounting seat is used for being connected with a Z-axis mounting plate of a machine tool, and a liquid outlet of the water jacket is attached to the side surface of the workpiece blank and used for enabling electrolyte to enter a gap between the machining cathode and the workpiece blank;
the regulating plate group and the pressure acquisition point group are both arranged on the end face, far away from the water jacket, of the processing cathode, and the regulating plate group is used for regulating the flow rate of the electrolyte according to pressure data acquired by the pressure acquisition point group.
Further, the water jacket is located at one side of the base and the electrolyte therein adopts a lateral flow.
Furthermore, the machining end face of the machining cathode is matched with the profile of the workpiece blank.
Furthermore, the initial machining gap between the machining cathode and the workpiece blank is 0.1-0.3 mm.
(3) Advantageous effects
In conclusion, the invention improves the centralized etching and removing capability and the localized processing level of the large-area electrolytic processing by implementing key technical measures such as gradient adjustment of the electrolyte pressure along the direction vertical to the electrolyte flow of the large-area molded surface at the electrolyte outlet position of the processing area, addition of small-voltage reverse pulse in the intermittent window period of forward pulse application, comprehensive design of continuous processing/one-step forming process parameters according to the material removing characteristics in the processing process and the like, ensures the safe and stable processing of the processing process and realizes the high-efficiency, high-precision and high-quality processing of the large-area molded surface.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic flow chart of a method for regulating and controlling a large-area profile electrochemical machining flow field according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating pressure regulation of a flow field region in a method for regulating a large-area profile electrochemical machining flow field according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a reverse pulse application scheme provided by an embodiment of the present invention;
FIG. 4 is a schematic view of a combination of continuous processing/single forming process modes provided by an embodiment of the present invention;
FIG. 5 is a schematic diagram of a first relationship provided by an embodiment of the present invention;
FIG. 6 is a diagram illustrating a second relationship provided by an embodiment of the present invention;
FIG. 7 is a schematic structural diagram of a large-area profile electrochemical machining tool according to an embodiment of the present invention;
FIG. 8 is a rear view of a large-area profile electrochemical machining tool according to an embodiment of the present invention;
fig. 9 is a schematic structural diagram of a processed cathode provided in an embodiment of the present invention.
In the figure:
1-cathode mounting base; 2-processing a cathode; 3-small end pressing plate; 4-a base; 5-workpiece blank; 6-big end pressing plate; 7-water jacket; 8-group of conditioning sheets; 9-pressure collection point group; 10-electrolyte outlet.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following detailed description of the embodiments and the accompanying drawings are provided to illustrate the principles of the invention, but are not intended to limit the scope of the invention, i.e., the invention is not limited to the embodiments described, but covers any modifications, alterations and improvements in the parts, components and connection means, without departing from the spirit of the invention.
It should be noted that, in the present application, the embodiments and features of the embodiments may be combined with each other without conflict. The present application will be described in detail below with reference to the embodiments with reference to the attached drawings.
Fig. 1 is a schematic flow chart of a method for regulating and controlling a large-area profile electrochemical machining flow field according to an embodiment of the present invention, where the method may include the following steps:
s100, adjusting the pressure gradient of an electrolyte outlet by adopting a flow resistance type regional pressure method;
s200, adding a reverse pulse in an intermittent window period applied by the forward pulse;
s300, determining the parameters of the electrolytic machining process according to the material removal characteristics in the machining process.
In the embodiment, the directional flow guiding method is carried out on the two sides of the molded surface processing area along the flowing direction of the electrolyte, so that the direction regulation of the whole flow field is realized, the lateral overflow of the electrolyte is prevented, the pressure attenuation of the electrolyte is reduced, and the utilization efficiency of the electrolyte is improved; and a series of adjusting sheet groups are arranged at an electrolyte outlet vertical to the flowing direction of the electrolyte, and a flow resistance type regional pressure adjusting method is adopted to realize the field flow rate control of a large-area flow field.
In some optional embodiments, in step S100, the adjusting the pressure gradient of the electrolyte outlet by using a flow resistance type zone pressure method specifically includes the following steps:
s101, arranging a branch partition adjusting device on an electrolyte outlet in a direction vertical to the electrolyte flowing direction;
s102, arranging a plurality of pressure collecting points along the process according to the change condition of the electrolyte flow field state caused by the shape change of the workpiece processing surface in the processing process;
s103, adjusting the space size of the flow dispersion area at the on-way electrolyte outlet in real time according to the pressure change condition of each pressure acquisition point.
Specifically, in the electrolytic machining of the large-area molded surface, a branch subarea adjusting device is arranged on the way of an electrolyte outlet which is approximately vertical to the flowing direction of the electrolyte, a series of pressure acquisition points are arranged on the way according to the state change condition of the electrolyte flow field caused by the shape change of the workpiece processing surface in the machining process, and the space size of a flow area at the electrolyte outlet on the way is adjusted in real time according to the pressure level change condition of each acquisition point, so that the uniformity of the flow field of each area of the large-area molded surface is ensured.
In some optional embodiments, in step S200, a reverse pulse is added during the pause window of the forward pulse application, specifically:
the reverse pulse is applied during the intermittent period of the forward pulse processing, so that a positive pulse and a reverse pulse are alternately applied to the workpiece anode and the tool cathode.
Specifically, during the reverse pulse action, the direction of the current is changed, the oxidation reaction occurs on the surface of the cathode of the tool, and the pulse current has a pulse stirring effect on the electrolyte, so that the removal and depolarization of the adsorption layer of the cathode of the tool are facilitated, and the surface of the cathode of the tool is effectively purified; the surface of the workpiece is subjected to a reduction reaction, so that anode polarization is favorably relieved, the activation process of the anode passivation surface in the last processing period is accelerated, the activation degree is improved, the dissolution condition is further improved, and the stability of the electrolytic processing process under a micro gap can be improved.
As shown in fig. 3, there are three main ways of applying reverse pulses in bipolar pulse current electrochemical machining: positive pulse falling edge application, positive pulse (group) rest period application, and positive pulse falling edge and positive pulse (group) rest period application are simultaneously carried out.
In some alternative embodiments, the application of the reverse pulse comprises: positive pulse falling edge application, positive pulse pause period application, and simultaneous positive pulse falling edge and positive pulse pause period application.
The first reverse pulse application mode in fig. 3 is adopted, that is, a reverse pulse is applied to the falling edge of the forward pulse, so as to realize efficient, high-precision and high-quality processing of a large-area cavity.
In some optional embodiments, in step S300, according to the material removal characteristics in the machining process, the electrochemical machining process parameters are determined, specifically:
the processing process is divided into three stages of removing a thin oxide layer on the surface, quickly leveling and precisely forming, and processing technological parameters of the corresponding stages are respectively determined.
As shown in fig. 4, the machining process is designed in segments, which mainly includes three stages of removing a thin oxide layer on the surface, rapidly leveling and precisely forming, and corresponding machining parameters are designed for the emphasis points of different stages.
In some optional embodiments, the processing process is divided into three stages of removing a thin surface oxide layer, rapidly leveling and precisely forming, and processing technological parameters of the corresponding stages are respectively determined, and the method specifically comprises the following steps:
s301, determining the electrochemical machining voltage and the cathode feeding speed required by the removal, the rapid leveling and the precise forming of the thin oxide layer on the surface through a machining test;
s302, respectively determining a first relation curve and a second relation curve according to the electrolytic machining voltage and the cathode feeding speed;
s303, importing the first relation curve into an electrolytic machining power supply control system, and importing the second relation curve into an electrolytic machining machine tool control system;
s304, during electrolytic machining, the electrolytic machining power supply control system outputs machining voltage according to the first relation curve, and the machine tool spindle drives the cathode feeding speed to automatically adjust along with the change of machining time according to the second relation curve;
the first relation curve is a relation curve of processing voltage and processing time, and the second relation curve is a relation curve of cathode feeding speed and processing time.
Specifically, (1) determining the electrochemical machining voltage value and the cathode feeding speed required by the removal, rapid leveling and precise forming of the thin oxide layer on the surface of the target object through a machining test, wherein the machining process is in a safe and stable state;
(2) based on the obtained data of the processing voltage and the cathode feeding speed, a relation curve of the processing voltage-processing time and the cathode feeding speed-processing time is designed, as shown in fig. 5 and 6;
(3) leading the relation curve of machining voltage-machining time into an electrolytic machining power supply control system, and leading the relation curve of cathode feeding speed-machining time into an electrolytic machining machine tool control system;
(4) after the machining is started, the power supply control system outputs machining voltage according to a relation curve of machining voltage-machining time, and the machine tool spindle drives the cathode feeding speed to automatically adjust according to the change of the relation curve of the cathode feeding speed-machining time along with the machining time.
Fig. 7 is a schematic structural diagram of a large-area profile electrochemical machining tool provided in an embodiment of the present invention, where the tool may include a cathode mounting seat 1, a machining cathode 2, a small-end pressing plate 3, a base 4, a large-end pressing plate 6, a water jacket 7, a regulating plate group 8, and a pressure collection point group 9; one end of the machining cathode 2 is fixed on the cathode mounting seat 1, the small end pressing plate 3 and the large end pressing plate 6 are both mounted on the upper end face of the base 4 and used for fixing the workpiece blank 5 on the base 4, the machining cathode 2 is in contact with the workpiece blank 5 for tool setting and is positioned between the small end pressing plate 3 and the large end pressing plate 6 so that electrolyte can flow directionally along the molded surface;
the cathode mounting seat 1 is used for being connected with a Z-axis mounting plate of a machine tool, and a liquid outlet of the water jacket 7 is attached to the side surface of the workpiece blank 5 and used for enabling electrolyte to enter a gap between the machining cathode 2 and the workpiece blank 5;
the adjusting sheet group 8 and the pressure collection point group 9 are both arranged on the end face, far away from the water jacket 7, of the processing cathode 2, and the adjusting sheet group 8 is used for adjusting the flow rate of the electrolyte according to pressure data collected by the pressure collection point group 9.
In the above embodiment, the cathode mounting base 1 is connected with a Z-axis mounting plate of a machine tool, a machining power supply negative cable is connected with the cathode mounting base 1 through a compression screw, and the machining cathode 2 is fixed on the cathode mounting base 1 through a screw; the base 4 is fixed on a machine tool workbench through screws, a processing power supply anode cable is communicated with the base 4 through a compression screw, and a workpiece blank 5 is fixed on the base 4 through a small-end pressing plate 3 and a large-end pressing plate 6; the liquid outlet of the water jacket 7 is tightly attached to the side surface of the workpiece blank 5, so that the electrolyte flows through the space between the processing cathode 2 and the workpiece blank 5 at a high speed, and is discharged out of the processing area through the electrolyte outlet 10 to take away processing products, bubbles, heat and the like.
The small-end pressing plate 3 and the large-end pressing plate 6 are used for performing fence type blocking on the two sides of the processed cathode 2, so that the electrolyte flows along the molded surface directionally, the electrolyte is prevented from splashing from a processing area to non-processing areas on the two sides, the pressure attenuation of the electrolyte is reduced, and the utilization efficiency of the electrolyte is improved.
Through a processing test, according to the material removal rate, the quality of the processed surface of the test piece and the pressure data of the pressure acquisition point group 9, the pneumatic or hydraulic actuator is utilized to adjust the adjusting plate group 8 up and down, and a flow resistance type regional pressure adjusting method is utilized to realize the field flow rate control of a large-area flow field meeting the processing requirement.
In some alternative embodiments, the water jacket 7 is located on one side of the base 4 and the electrolyte therein employs a lateral flow. Wherein, because the processing area is large, when the electrolyte positive water flows, the electrolyte at the central part of the processing area can not be updated in time, and the electrolysis products are accumulated, so that the stable processing is difficult to realize; the processing area can be effectively washed by adopting the lateral flow, the generated electrolytic product can be taken away in time, and the smooth processing process is ensured.
In alternative embodiments, as shown in fig. 9, the machining end face of the machining cathode 2 is adapted to the profile of the workpiece blank 5. Specifically, since the work blank 5 is finally formed into a blade, the machining end face of the machining cathode 2 is in a concave arc shape.
In some alternative embodiments, the machining gap between the machining cathode 2 and the workpiece blank 5 is 0.1 to 0.3mm. The initial machining gap is determined according to the size of the machining area and the complexity of the shape, and is preferably 0.2mm.
Examples
The processing object in the regulation and control method of the embodiment is a large-size profile, the material is TC4, the size of the profile is about 101 × 280mm, and the processing tool is shown in fig. 7.
(1) Designing a workpiece blank 5: the molded surface part of the workpiece blank is a flat plate, one end of the workpiece blank is provided with a mounting platform, and a clamping reference surface is designed on the mounting platform;
(2) Processing a cathode and designing a tool: the processing cathode 2 and the tool are both made of 316L stainless steel, and the shape of the processing end face of the cathode is similar to the shape of the molded surface of a workpiece blank, as shown in FIG. 8; the device mainly comprises a cathode mounting seat 1, a processing cathode 2, a small end pressing plate 3, a base 4, a large end pressing plate 6 and a water jacket 7; the electrolyte adopts a lateral flow form and enters a gap between the machining cathode 2 and the workpiece blank 5 through the water jacket 7, so that the machining flow field is uniform and consistent;
(3) Installation and adjustment of the processing cathode, the tool and the workpiece blank: connecting the cathode mounting seat 1 with a Z-axis mounting plate of a machine tool, communicating a processing power supply cathode cable with the cathode mounting seat 1 through a compression screw, and fixing a processing cathode 2 on the cathode mounting seat 1 through a screw; the base 4 is fixed on a machine tool workbench through screws, a processing power supply anode cable is communicated with the base 4 through a compression screw, and a workpiece blank 5 is fixed on the base 4 through a small-end pressing plate 3 and a large-end pressing plate 6; a liquid outlet of the water jacket 7 is tightly attached to the side surface of the workpiece blank 5, so that the electrolyte flows through the space between the processing cathode 2 and the workpiece blank 5 at a high speed and is discharged out of a processing area through an electrolyte outlet 10 to take away processing products, bubbles, heat and the like;
(4) Adjusting the electrolyte pressure in the processing area: the small-end pressing plate 3 and the large-end pressing plate 6 are used for performing fence type blocking on the two sides of the processed cathode 2, so that the electrolyte flows along the molded surface directionally, the electrolyte is prevented from splashing from a processing area to non-processing areas on the two sides, the pressure attenuation of the electrolyte is reduced, and the utilization efficiency of the electrolyte is improved.
Through a machining test, according to the material removal rate, the quality of the machined surface of the test piece and the pressure data of the pressure acquisition point group 9, the pneumatic actuator is used for adjusting the regulating sheet group 8 up and down, and a flow resistance type regional pressure regulating method is used for realizing the field flow rate control of a large-area flow field meeting the machining requirement;
(5) Electrolytic machining: the machining cathode 2 and the workpiece 5 are subjected to contact tool setting, then the movement of the machining cathode 2 is controlled according to a preset initial machining gap, the current value when the machining gap delta =0.08mm is obtained through a test and is 4200A, a curve of machining voltage-machining time and a curve of cathode feed speed-machining time are set, and machining is carried out according to the curves in the graphs in the figures 5-6 until the requirements of the pattern shape and the depth are met.
(6) Electrolytic machining toolThe technological parameters are as follows: 15% of NaNO 3 Electrolyte, reverse pulse voltage is 1V, and pulse opening angle is 165-200 degrees; the electrolyte pressure is 0.8MPa; temperature of the electrolyte: 25 ℃; pulse width t =0.25ms; pulse duty cycle 60%; initial machining gap delta 0 ＝0.2mm。
It should be clear that the embodiments in this specification are described in a progressive manner, and the same or similar parts in the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. The present invention is not limited to the specific steps and structures described above and shown in the drawings. Also, a detailed description of known process techniques is omitted herein for the sake of brevity.
The above are merely examples of the present application and are not intended to limit the present application. Various modifications and alterations to this application will become apparent to those skilled in the art without departing from the scope of this invention. Any modification, equivalent replacement, improvement or the like made within the spirit and principle of the present application shall be included in the scope of the claims of the present application.
Claims (9)
1. A regulation and control method for a large-area molded surface electrolytic machining flow field is characterized by comprising the following steps:
adjusting the pressure gradient of an electrolyte outlet by adopting a flow resistance type regional pressure method;
adding a reverse pulse during an intermittent window of forward pulse application;
determining the parameters of the electrolytic machining process according to the material removal characteristics in the machining process;
the method for adjusting the pressure gradient of the electrolyte outlet by adopting the flow resistance type regional pressure method comprises the following steps:
a branch partition adjusting device is arranged on the electrolyte outlet in a direction vertical to the electrolyte flowing direction;
according to the change situation of the electrolyte flow field state caused by the shape change of the workpiece processing surface in the processing process, a plurality of pressure collection points are arranged along the process;
and adjusting the space size of the flow dispersion area at the on-way electrolyte outlet in real time according to the pressure change condition of each pressure acquisition point.
2. A method of regulating a large area profile electrochemical machining flow field as claimed in claim 1, wherein reverse pulses are added during the intermittent window of forward pulse application, specifically:
the reverse pulse is applied during the intermittent period of the forward pulse processing, so that a positive pulse and a reverse pulse are alternately applied to the workpiece anode and the tool cathode.
3. A method of regulating a large area profile electrochemical machining flow field according to claim 1, wherein the reverse pulse is applied in a manner comprising: positive pulse falling edge application, positive pulse pause application, and simultaneous application of positive pulse falling edge and positive pulse pause.
4. A method for regulating and controlling a large-area profile electrochemical machining flow field according to claim 1, wherein the electrochemical machining process parameters are determined according to the material removal characteristics during machining, and specifically are:
the processing process is divided into three stages of removing a surface thin oxide layer, quickly leveling and precisely forming, and processing technological parameters of the corresponding stages are respectively determined.
5. The method for regulating and controlling the large-area profile electrochemical machining flow field according to claim 4, wherein the machining process is divided into three stages of removing a thin oxide layer on the surface, rapidly leveling and precisely forming, and machining process parameters of the corresponding stages are respectively determined, and the method specifically comprises the following steps:
determining the electrolytic machining voltage and the cathode feeding speed required by removing the thin oxide layer on the surface, quickly leveling and precisely forming through a machining test;
respectively determining a first relation curve and a second relation curve according to the electrolytic machining voltage and the cathode feeding speed;
leading the first relation curve into an electrolytic machining power supply control system, and leading the second relation curve into an electrolytic machining machine tool control system;
during electrolytic machining, the electrolytic machining power supply control system outputs machining voltage according to the first relation curve, and a machine tool spindle drives the cathode feeding speed to automatically adjust according to the change of the second relation curve along with machining time;
the first relation curve is a relation curve of processing voltage and processing time, and the second relation curve is a relation curve of cathode feeding speed and processing time.
6. The large-area molded surface electrolytic machining tool is characterized by comprising a cathode mounting seat (1), a machining cathode (2), a small-end pressing plate (3), a base (4), a large-end pressing plate (6), a water jacket (7), a regulating plate group (8) and a pressure collecting point group (9); one end of the machining cathode (2) is fixed to the cathode mounting seat (1), the small end pressing plate (3) and the large end pressing plate (6) are mounted on the upper end face of the base (4) and used for fixing a workpiece blank (5) on the base (4), the machining cathode (2) is in contact with the workpiece blank (5) for tool setting and is located between the small end pressing plate (3) and the large end pressing plate (6) so that electrolyte can flow directionally along a molded surface;
the cathode mounting seat (1) is used for being connected with a Z-axis mounting plate of a machine tool, and a liquid outlet of the water jacket (7) is attached to the side surface of the workpiece blank (5) and is used for enabling electrolyte to enter a gap between the machining cathode (2) and the workpiece blank (5);
the adjusting plate group (8) and the pressure acquisition point group (9) are both arranged on the end face, far away from the water jacket (7), of the machining cathode (2), and the adjusting plate group (8) is used for adjusting the flow rate of the electrolyte according to pressure data acquired by the pressure acquisition point group (9).
7. The large-area profile electrolytic machining tool according to claim 6, wherein the water jacket (7) is positioned on one side of the base (4) and the electrolyte in the water jacket flows in a lateral direction.
8. The large-area profile electrolytic machining tool according to claim 6, wherein the machining end face of the machining cathode (2) is matched with the profile of the workpiece blank (5).
9. The large-area profile electrolytic machining tool according to claim 6, wherein the initial machining gap between the machining cathode (2) and the workpiece blank (5) is 0.1-0.3mm.
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